Classic Auto Air Install Details

[TheBMan]

My big winter project was installing air conditioning into my 70 Monte Carlo. There are multiple companies to choose from but I chose the Classic Auto Air system because it utilizes the factory dash vents rather than providing additional vents that you then mount under the dash. I wanted to maintain a stock appearance (as much as possible) and this accomplishes that from the vent perspective. I'm pretty sure this is the same reason that @MCfan chose the CAA system. His write-up is somewhere on this site but I wasn't able to find it. Maybe Dennis will post a link to his as well as it was a great write up with lots of photos.

The system comes with an entirely new heater box to replace the existing one. It also comes with block-off plates for the large Astro vents in the dash. You then run new flexible tubing to the vents from the heater box under the dash/behind the glove box. Additionally, it comes with new center dash vents to replace the "Chevrolet" filler plate. Note that when you buy the kit from CAA, they don't list a Monte Carlo kit specifically. If you call them, they will provide extra long lines to accommodate but you have to cut them to length and get them crimped on your own.

The HVAC dash control panel that's included with the kit works nicely but again, it doesn't look like it came with car. It simply isn't period correct in terms of style, which a lot of guys won't mind, but again, I wanted to maintain the stock look as much as possible. I'm pretty good with Adobe Illustrator so I created a vector image file using the font and colors of the original panel. I printed that on card stock and then encased it behind a clear plastic panel that I had laser cut. A friend has a small laser cutting machine so I just measured everything out and he cut it for me. I then modified the original chrome knobs by drilling and adding a set screw so they would stay in place on the CAA sliders and fan switch.

The new panel for the firewall comes in plain ole black and there is nothing fancy or 'finished' about it. So I lightly scuffed it and painted it satin black. I also found some rubber grommets to add to give it a better look. I also replaced the stainless screws with black screws, which look much better.

The kit comes with the modern Sanden compressor (the small one you always see on retro-fitted classics). I chose to use the modern S6 (also a Sanden) compressor rather than the antiquated and inefficient A6 that came with the car originally. The S6 is a direct bolt-on using the factory brackets but the body isn't smooth like the A6. It also only comes in aluminum (silver) so I had the S6 powder coated satin black and then I fabricated a cylindrical cover to encase it. Those wide bands at each end are actually 1/2" tie straps that I lightly "sanded" with a Scotchbrite pad to give it a soft, satin finish. The tie strap tabs are hidden, unseen under the compressor. Last, I replaced the stainless screws on the compressor clutch with black so they don't stand out as much. I also replicated the original Frigidaire/GM spec decal in Illustrator and had it printed at my local print shop. The decal has the correct compressor serial number and R-134a charge amount (1.5lbs). 

The kit comes with a heather control valve that is absolutely hideous to look at (see attached picture) so I had a enclosure 3-D printed and then ran the hoses into the enclosure and hid the clamps inside.

Other issues to overcome... these kits are suppose to be direct fit but they are not. LOTS of modifications/fabrication had to be done. For example, the kit says to mount the condenser to the existing mounting points on the radiator support. Those mounting points did not exist on my car and I had to drill multiple holes. Measure 5 times, drill once! Also, the compressor manifold that comes with the kit did fit the S6 compressor but did not provide enough clearance to the mounting bracket that goes from the back of the compressor to the intake manifold. There is a swivel manifold available, and it works, but I didn't like the way it looked once I had the lines crimped. Instead, I bought an original manifold with [old] lines from @Dtret and had new lines put on it. Additionally, there was some bending of the aluminum tubing that connects the condenser, receiver dryer, and lines in front of the radiator. I took my time and bent them to fit using a tubing bender so it looked like it came that way.

One thing I haven't remedied yet... when I got the car, I repaired the original radio and installed a new center speaker so that everything worked. Now there is no room for the center speaker because of all the vent tubing. I might be able to go to two-speaker setup on the outer edge of the dash but that will involve another dash pad, or modifying the one I have, because of the holes for the sound to go through - I only have holes in the center; outer holes would have to be drilled.

I will say that that the guys at Classic Auto Air were great. When I had questions, they were responsive and had good info. No complaints there. The system was blowing 40° air on a 95° day last weekend (while rolling down the road).

One last thing... I took my time with this project. I started in February and didn't finish until mid-May. Some of that was me moving slow to make sure everything was perfect (as perfect as I could get it), some of it was waiting for parts and whatnot. I think if you wanted to bang out an install, it could be done in a solid weekend if you were really committed to it and you wanted to use the kit exactly as it came. Of course that's assuming there is no lengthy fab work or modifications and you either have a hose crimp tool or know someone/place that can do it. I'm not sure it's realistic to expect it to just bolt in straight out of the box. IMHO

 I probably left some stuff out so if anyone has questions, feel free to post here or PM me. As always, the guys in this group were invaluable during this install. 💪

[7tonemonte]

Your newly printed board looks great.  
  Seems like a nice kit as after this weekend in Carlisle I think I have the new project fig😅ured out 

[TheBMan]

9 hours ago, 7tonemonte said:

Your newly printed board looks great.  
  Seems like a nice kit as after this weekend in Carlisle I think I have the new project fig😅ured out 

@7tonemonte If you do the project and you want the files for the faceplate to take to a printer, PM me. I can also send you the name of the guy who laser printed the clear plastic overlay piece. 

[S.Maug]

looks good, hope it cools great!  my Florida 70 Bloo 402 has vintage air system. fits good, looks great, and cools fantastic.  again, great job...!!

[TheBMan]

50 minutes ago, S.Maug said:

looks good, hope it cools great!  my Florida 70 Bloo 402 has vintage air system. fits good, looks great, and cools fantastic.  again, great job...!!

Thanks! 40° air from the vents on a 95° day.  

[S.Maug]

excellent results!

[S.Maug]

I say that because as an automotive a/c tech for over 40 plus years around 30-degree difference from outside ambient air temp was considered good, but even myself have been surprised with the cooling factors that I have obtained sometimes.  fantastic job.